Empowering operations with PI System

Presented by

© Copyr i gh t 2013 OSIso f t , LLC.

Empowering

operations with

PI System

Marcin Błasiak – Chief Production

Management Systems Specialist


Agenda

• About PGNiG Termika

• PI System at PGNiG Termika – business case

• Examples of PI applications

• Conclusions

2


History

3

• 1904 – first power plant in Warsaw – CHP Powiśle

• 1914 – CHP pruszków

• 1954 – first turbine in CHP Żerań

• 1961 first turbine in CHP Siekierki

• 1974 – HOB Wola

• 1983 – HOB Kawęczyn

• 2000 – Vattenfall Heat Poland

• 2012 – PGNiG Termika


About PGNiG Termika

4

• Since January 2012 Vattenfall Heat

Poland became PGNiG Termika

• 5 Power plants (3 CHP’s and 2 HOB’s

• First Heat Accumulator in Poland CHP

Siekierki

• PGNiG Termika produces over 40 mGJ of

heat covering 70 % of Warsaw’s heat

demand

• Annual electricity sales covers 50 % of

Warsaw’s electricity consumption

(cogeneration)

• PGNiG Termika supports district heating

grid owned by Dalkia Polska

• Fuels: hard coal, biomass

186 MWt

9 MWe

1 554 MWt

298 MWe 465 MWt

2 014 MWt

622 MWe

465 MWt

1904 – first Power Plant in Warsaw


Background

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The beginning …

5 independent Power Plants

Lack of detailed central planning

Lack of central monitoring of production process

Not optimal production process

Target… efficiency improvement

The beginning of Production Dispatch

Need for detailed information exchange with partners

A lot of calculations & reporting… very quickly

Quick access to information about production process

Need for production process optimization


Challenge

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Business case

7


Areas of benefits

8


Infrastructure

9


IT Systems at PGNiG Termika

10


Implementation of PI System

11



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Benefits: Monitoring & reporting

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Benefits: Monitoring & reporting

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Benefits: Optimization

16


Benefits: Operating Point

17

Efficiency report - boiler losses

0%

20%

40%

60%

80%

100%

08-07-

10

08-07-

11

08-07-

12

08-07-

13

08-07-

14

08-07-

15

08-07-

16

08-07-

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08-07-

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08-07-

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08-07-

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Time

Loss 1 Loss 2 Loss 3 Loss 4 Loss 5 Loss 6 Loss 7 Loss 8 Loss 9 Loss 10

On-line efficiency monitoring

helps us to operate only the most

efficient units at their optimal point

and save up to 2…3% of fuel


Benefits: KPI monitoring

18



19

KPI monitoring helps us to define

strategic goals and take

the right actions

In the right time



20


Benefits: Condition based maintenance

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By finding relationships between

device operational parameters

and overall eficiency we can easily

Indicate device failure or

bad condition


Benefits: Efficiency monitoring

22

Instead of complex measurement procedure twice a year we provide online calculation

(in connection with neural networks) to see how device (boiler behaves)

On-line calculation = another 50.000 EUR saving per year


Variable cost in function of load Variable cost in function of time

Decision point.

Which boiler to

shut down ?

Benefits: Variable cost monitoring

23

On-line variable cost

Calculation gives possibility

to choose between optimal

devices set

to provide optimal configuration

Optimal configuration =

ca. 50.000 EUR saving per year


Summary of benefits

24


Key benefit…

What is the real benefit of PI system

implementation from the perspective of a decade

of operation?

25


Organization transformation

• „How can PI help us?” instead of „We need to

implement something…”

• „Always think about synergies before you act”

• Information brings more value to organization

than just storing data

• We should always give users freedom of

organizing their workspace.

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Transformation into a global system

27

Process monitoring

Production settlements

Reporting

KPI definition and monitoring

Advanced performance

calculation Communication with external

partners

Production & Asset management

PI

Other IT

systems:

- Data warehouse

- SCADA systems

- Physical

connections

- ERP systems

- Dedicated

applications

PI:

- Data validation

- ACE calculations

- Integration via

OLEDB / web

services

- AF for process

representation

Areas of operation Past Now


New areas of development

28

Data exchange with

partners

PI as a system for

settlements

Communication event

handling

Before

After

- Data exchage via industrial

protocols

- Number of data streams

limited to end-edvices

capacity

- Scalability requires

hardware modification

- Communication via Web

services

- Large scalability with

assets consumption

Before

After

- Settlements done by many

systems

- Complicated data

exchange between

settlement procesess

- PI as a settlement system

- Data validates by ACE

- No data exchange

problems

Before

After

- Communication to shift

engineers by email – not

everybody know about

production strategy

- Shift reports in excel

sheets

- Communication via PI

usiNg data streams for

information visualization

- Shift reports in PI


Marcin Błasiak

[email protected]

Chief Production Management System Specialist

PGNiG Termika

29

mailto:[email protected]

mailto:[email protected]

© Copyr i gh t 2013 OSIso f t , LLC. 30

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